Dixon 36 / 968999539 Safety And Operating Manual Download

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Safety Instructions

and

Operator’s Manual

Models ZTR

44/968999538

ZTR

36/968999539

ZTR

42/968999546

ZTR

44/968999547

SPEEDZTR

™

ZTR

Summary of Contents for 36 / 968999539

Page 1: ...Safety Instructions and Operator s Manual Models ZTR 44 968999538 ZTR 36 968999539 ZTR 42 968999546 ZTR 44 968999547 SPEEDZTR ZTR ...

Page 2: ...ad this Operator s Manual carefully It contains valuable information that is necessary for the safe operation of the machine Observe all safety rules and become completely familiar with the controls The information contained in this manual applies to all Dixon ZTR SpeedZTR mowers See your authorized Dixon dealer for warranty service parts and repairs or to answer questions you have about your new ...

Page 3: ...on Drive System 20 Blade Drive 21 Throttle Control Lever 21 Choke Control 21 Circuit Breaker 21 Cut Height Lift Lever 22 OPERATION INSTRUCTIONS 23 33 Starting 24 Towing 25 Testing Safety Systems 26 Mowing with Attachments 28 31 Side discharge 32 Grass height 33 CARE AND MAINTENANCE 34 45 Cutter blades 35 Engine 36 Battery 36 Tires 37 Lubrication 37 38 Belts 39 Neutral adjustment 40 Deck leveling 4...

Page 4: ...Over Back Over Pictured below are the most common causes of injury to the operator or bystander Please read and understand this manual to prevent injuries WARNING Riding lawn movers if improperly operated can cause serious injury or death ...

Page 5: ...ently hazardous situation which if not avoided will result in death or serious injury WARNING highlighted in orange indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION highlighted in yellow indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It may also be used to alert against unsafe p...

Page 6: ...the area Never direct discharged material toward anyone Avoid discharging against a wall or obstruction Material may ricochet back toward the operator Stop the blade s when crossing gravel surfaces Do not operate the mower without either the entire grass catcher or the deflector in place This will decrease the possibility of injury from objects being thrown by the mower blades Never carry passenge...

Page 7: ...own before turning to reduce the risk of tip over Watch for traffic when operating near or crossing roadways Use extra care when loading or unloading the mower into a trailer or truck Always wear eye protection when operating machine Data indicates that operators age 60 years and above are involved in a large percentage of riding mower related injuries These operators should evaluate their ability...

Page 8: ...ven terrain that could overturn the mower Tall grass can hide such obstacles Use slow speed Tires may lose traction on slopes even though the brakes are functioning properly Avoid starting or stopping on a slope If tires lose traction disengage the blades and proceed slowly down the slope Keep all movement on the slopes slow and gradual Do not make sudden changes in speed or direction Use extreme ...

Page 9: ...s Unstable ground may cause loss of control Do not mow on wet grass Reduced traction could cause sliding Do not try to stabilize the mower by putting your foot on the ground Do not use grass catcher or other attachments on steep slopes The added weight may change the stability of the mower thus creating the potential for tip over WARNING Failure to observe the following instructions could result i...

Page 10: ...wer free of grass leaves and other debris buildup If gasoline is spilled do not attempt to start the engine Move mower away from the area of the spill Do not create any source of ignition until gas vapors have dissipated Wipe up spilled fuel and dispose of waste properly If fuel is spilled on clothing change clothing immediately Before storing allow mower to cool Clean fuel and oil spillage Never ...

Page 11: ...aused by static electricity Never fill containers inside a vehicle or on a truck or trailer bed with a plastic liner Always place containers on the ground away from your vehicle before filling When practical remove fuel powered equipment from the truck or trailer and refuel it on the ground If this is not possible refuel such equipment on a trailer with a portable container rather than from a fuel...

Page 12: ...and keep children under the watchful care of another responsible adult Be alert and turn mower off if bystanders children or pets enter the area Before and during backing look BEHIND and DOWN for small children Never carry children as passengers They may fall off and be seriously injured or interfere with safe mower operation Never allow children to operate the mower Use extra care when approachin...

Page 13: ...Never make adjustments or repairs with the engine running unless otherwise specified Grass catcher components are subject to wear damage and deterioration that could expose moving parts or allow objects to be thrown Frequently check components Replace with original equipment parts when necessary When servicing blades wrap blades or wear gloves and use extra caution Batteries contain sulfuric acid ...

Page 14: ... reimbursement to dealers based on published Dixon flat rate schedule 7 Warranty does not apply to damage in transit or incidents of misuse negligence accidents or alteration The use of parts or components other than those supplied by Dixon VOIDS ALL WARRANTY 8 Battery warranty is limited to 1 year from mower manufacture date 9 The following items are not covered by this warranty policy a Routine ...

Page 15: ...head valve air cooled gasoline vertical shaft cast iron cylinder full pressure lube with spin on filter Electric key switch operation with safety interlocks on park brake steering levers and blade drive Front 11 x 4 00 5 smooth tread 16 21 PSI 110 145 kPa Rear 18 x 7 50 8 4 ply turf tread 8 14 PSI 55 97 kPa Fuel 4 5 gallon 17 liters Engine Oil 1 3 quarts 1 3 liters Width 43 109 cm maximum track wi...

Page 16: ...static drive with cooling fan 16 5 HP Briggs Stratton Intek 4 cycle single cylinder overhead valve air cooled gasoline vertical shaft cast iron cylinder full pressure lube with spin on filter Electric key switch operation with safety interlocks on park brake steering levers and blade drive Front 11 x 4 00 5 smooth tread 16 21 PSI 110 145 kPa Rear 18 x 8 50 8 4 ply turf tread 8 14 PSI 55 97 kPa Fue...

Page 17: ...ZT self contained hydrostatic drive 20 HP Briggs Stratton twin cylinder overhead valve air cooled gasoline vertical shaft full pressure lube with air filter aluminum head and block withcast iron cylinder liners Electric key switch operation with safety interlocks on park brake steering levers and blade drive Front 11 x 4 00 5 smooth tread16 21 PSI 110 145 kPa Rear 18 x 9 50 8 4 ply turf tread 8 14...

Page 18: ...r EZT self contained hydrostatic drive 20 HP Kohler single cylinder overhead valve air cooled gasoline vertical shaft full pressure lube with air filter aluminum head and block withcast iron cylinder liners Electric key switch operation with safety interlocks on park brake steering levers and blade drive Front 11 x 4 00 5 smooth tread16 21 PSI 110 145 kPa Rear 18 x 9 50 8 4 ply turf tread 8 14 PSI...

Page 19: ...you TURNING Turning is controlled by moving one control lever slightly forward or rearward of the other To turn left move left lever rearward of the right lever To turn right move right lever rearward of the left lever To turn on mower s own axis zero turning radius stop and move one lever to reverse position and the other to forward position BRAKING To brake mower move both levers in direction op...

Page 20: ...AKE The hand operated park brake is located on the operator s left To engage brake pull lever up to the rear To release brake move lever forward down NOTE Always set park brake before dismounting Release park brake before moving mower TRANSMISSION DRIVE SYSTEM Allows the mower to turn on its own axis ZERO TURNING RADIUS Each lever controls one side of the mower NOTE The pressure required to operat...

Page 21: ...ntrol should be set to MAXIMUM or wide open setting to insure adequate cooling of the engine and to maintain mower deck blade speed while mowing CHOKE CONTROL Choke for engine starting On the 36 and 42 models the choke is combined with the throttle See Fig 3 The 44 has a separate choke cable See Fig 4 CIRCUIT BREAKER Protection of the electrical system is by 1 15 amp circuit breaker If circuit bre...

Page 22: ...r portion of foot pedal until bottom of the pedal engages in deck positioning notch To lower deck push forward with right foot on top portion of foot pedal until bottom edge of pedal disengages deck positioning notch Lower deck to desired height and push bottom portion of foot pedal until bottom edge engages notch Never attempt to operate deck lift mechanism in any manner other than foot method de...

Page 23: ...t mower without applying park brake or stopping engine During initial operation learning to drive set throttle at slow speed Sound judgement by the operator will prevent accidents BEFORE OPERATING MOWER 1 Read engine manufacturer s operating and maintenance instructions 2 Read and observe all safety instructions on your mower and in the manual 3 Check engine oil 4 Check fuel cap to be sure it is i...

Page 24: ...n to RUN position 4 Move throttle to maximum speed position 5 Release park brake 6 Swing levers inward 7 Operate mower per CONTROL instructions on Page 19 NOTE When mowing with blades engaged set throttle control to the MAXIMUM or wide open setting to insure adequate cooling of the engine and to maintain mower deck blade speed WARNING Failure to observe the following instructions could result in s...

Page 25: ...ver attempt to move the lever with the engine running Lift the seat to access release levers Push the hydro release levers toward the rear of the machine and inward until notches lock in place on frame See Fig 4 Release park brake To engage the transmissions move the release levers outward so they return to normal position NOTE Before pushing or towing tractor transmission must be unlocked and par...

Page 26: ...ch to START ENGINE SHOULD NOT TURN OVER OR ATTEMPT TO START CONTROL LEVER SWITCH TEST 1 Disengage blade drive 2 Put park brake in ON position 3 Swing control levers inward 4 Turn ignition switch to START ENGINE SHOULD NOT TURN OVER OR ATTEMPT TO START NOTE If any safety check fails do not operate the mower until the system has been checked and repaired by an authorized Dixon dealer WARNING Failure...

Page 27: ... from bystanders start engine 2 Leave control levers in outward position and put park brake in OFF position 3 Rise slightly off seat Engine should stop 4 Restart engine 5 Leave control levers in outward position and put park brake in ON position 6 Make sure area is clear of bystanders Engage blade drive and rise slightly off the seat Engine should stop NOTE If any safety check fails do not operate...

Page 28: ...e engine speed control to the wide open or full setting 3 Place the mower deck cut height selector in either the top or second notch Never cut more than 19 mm to 1 25mm off the grass at any one time Attempting to cut more grass will result in the deck plugging and cause the engine to stall 4 It may be necessary to cut the lawn twice to achieve acceptable mulching performance especially on first cu...

Page 29: ... or impeller are still turning 8 Alternate mower direction This will evenly disperse the mulched grass clippings over the lawn for even fertilization If the mulching quality of the mower does not seem to be satisfactory try one or more of the following tips Raise the height of cut setting on your mower It may be necessary to cut your grass more frequently Operate the mower at a slower ground speed...

Page 30: ...underside of the deck and the attachment chutes Empty bags often to prevent plugging 4 If the grass is tall place the mower deck cut height selector in the top or second notch Initially overlap cutting swaths instead of a full swath with each pass 5 Keep the underside of the mower deck clean Frequent removal of dried grass and dirt will greatly assist in bagging of the clippings Never under any ci...

Page 31: ...r low hanging branches or other obstacles which might hit the catcher top while turning or backing the mower Use care when backing to avoid pushing the grass bags into the frame or hot exhaust muffler of the engine Fire could result Disengage blade and stop engine prior to clearing grass from either the discharge chute or grass catcher components Do not operate the mower with the grass catching at...

Page 32: ...f the grass is tall place the mower deck cut height lever in the top or second notch Initially overlap cutting swaths instead of a full swath with each pass Some applications may require a second cutting 4 Keep the underside of the mower deck clean Frequent removal of dried grass and dirt will allow the clippings to discharge correctly Never under any circumstances should you place hands or feet u...

Page 33: ...utting season As a rule of thumb never cut off more than one third of the total grass blade length Correct mowing height can reduce weeds and disease by 50 to 80 The following grass cut heights are based on adequate moisture conditions and normal thatch buildup in a healthy lawn Some locations and applications may require slightly different cut heights If in doubt consult your local lawn professio...

Page 34: ...n grass debris from muffler manifold area before each use Check air intake screen after each use Clean grass under deck after each use Check tire pressure every 10 hours Inspect blades for sharpness every 10 hours Clean air filter element every 25 hours Grease all zerks every 50 hours Check all belts every 50 hours Change engine crankcase oil after 5 hours break in and every 50 hours Change engine...

Page 35: ...removal 1 Safely raise front of mower 2 Hold or block blade from turning 3 Loosen blade bolt and remove blade 4 When replacing blade tighten blade bolt securely Be sure blade is centered on pilot before tightening See chart Deck Size Tighten to 36 44 50 60 ft lbs 68 81 Nm 42 35 ft lbs 48 Nm CAUTION Stop engine and remove ignition key for safety Wear heavy thick gloves when holding onto cutter blad...

Page 36: ...er Clean top of battery and terminals with baking soda and water Identify each cable so they can be reconnected to the correct terminal Disconnect cables from terminals ALWAYS disconnect ground cable first and reconnect last Charge battery NOTE Your Dixon mower comes equipped with a quick disconnect harness for the optional Dixon Battery Manager The Dixon Battery Manager maintains the proper charg...

Page 37: ...tires 42 18 x 8 50 8 8 14 PSI 55 97 kPa Rear tires 44 18 x 9 50 8 8 14 PSI 55 97 kPa Lug nuts or lug bolts should be checked regularly for tightness LUBRICATION CHASSIS 9 grease zerks LOCATIONS 2 front wheel axles 2 front wheel casters 2 deck lift shaft 2 control levers 1 mower deck hub SERVICE INTERVALS Every 50 hours of operation or once per season RECOMMENDED Name brand wheel bearing GREASE or ...

Page 38: ...6 Fill with oil see steps below NOTE Refer to engine manufacturer s recommendations for frequency of oil changes OIL FILL 1 Clean any spilled oil from engine and chassis 2 Make sure the hex stem on drain valve has been tightened 3 Refill engine with type and quantity of oil recommended by the engine manufacturer in engine literature NOTE Engine oil changes on the SpeedZTR will require replacement ...

Page 39: ...ive belt turn adjuster nut on threaded eyebolt Turning nut to the left will loosen the belt see Fig 10 Idler arm spring and eyebolt location appearance will vary on some models NOTE Engaging the blade clutch may produce a sharp high pitched chirp or squeal as the belt tension loading is absorbed by the idler system This is normal and not a sign of failure Belt deflection or movement should be appr...

Page 40: ...outward start the engine and release the park brake 3 Raise the seat to access hydro control linkage If right wheel creeps adjust right side linkage and vice versa Use procedure below see Fig 11 a Loosen jam nut on end of the coupler P N 539 116689 b If right wheel is creeping forward turn coupler counter clockwise until neutral is achieved clock wise for left side If right wheel is creeping back ...

Page 41: ... mid range cut height position 3 Turn blade so the two outer blade tips each point outward 4 Turn front adjuster nut s to level deck side to side 5 Turn all bladed so tips point to the front and rear 6 Turn rear adjuster nut s until blade is level to 6mm higher in the rear see Fig 12 NOTE This will place the mower deck in a base measurement position Additional adjustment may be required to achieve...

Page 42: ... from the other end of trailing rods 2 places and detach rods from deck 4 Remove hairpin cotter from top of front L Rods 2 places and detach L Rods from lift arms 5 Remove hairpin cotter from top of rear L Rods 2 places and detach L Rods from lift arms 6 Carefully raise and support front of chassis Slide mower deck to either side for removal Reverse procedure to reinstall deck assembly Fig 13 ...

Page 43: ...r mower start the engine and engage the mower deck for a few minutes to disperse any water that may have accumulated in bearings pulleys or fans NOTE Allow mower to cool before washing If bearings are hot they will draw moisture inside as they dry and cause corrosion SERIAL NUMBERS The serial number is located on frame at rear of engine WARRANTY Refer to warranty information page 15 PARTS SERVICE ...

Page 44: ... P N 539 122734 44 Deck Blade Hi Lift Fusion P N 539 119836 Super Hi Lift Fusion P N 539 119798 Standard Lift Fusion P N 539 119860 Gator Fusion P N 539 119862 Hi Lift P N 539 119858 Standard Lift P N 539 119859 Transmission Belt P N 539 120772 Deck Belt P N 539 118156 Factory installed ENGINE AIR AND OIL FILTERS Refer to Engine Operator s Manual for correct service intervals for engine oil change...

Page 45: ...rain old fuel replace with new fuel Clogged fuel line check fuel filter Fuel tank vent plugged clean fuel vent Faulty fuel pump consult dealer 5 ENGINE OVERHEATED Air intake screen or fins clogged clean intake screen and fins Oil level too low or too high adjust oil level Running engine too slow run engine faster 6 ENGINE RUNS BUT MOWER WON T MOVE FORWARD Drive belt broken or slipping replace driv...

Page 46: ...lades blocked by foreign material clean under deck 9 DRIVE SYSTEM Mower pulls to side check tire inflation consult dealer Mower creeps in neutral consult dealer Low on power check belt tension 10 CUT QUALITY Cut uneven left to right check tire inflation level deck Ends of grass blades are ragged sharpen blades Poor dispersal of grass clean deck check for loose belt Skips in spots check for loose b...

Page 47: ...___________________________ DATE OIL CHANGED DATE ENGINE TUNED ____________________ _____________________ ____________________ _____________________ ____________________ _____________________ ____________________ _____________________ ____________________ _____________________ ____________________ _____________________ ____________________ _____________________ Dixon 401 North Commerce Street Beat...

Page 48: ...on DIXON 401 Commerce Street Beatrice NE 68310 SpeedZTR 36 42 44 Part No 539 121042R1 10 04 06 WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm ...

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